1. For more detailed instructions, see the Getting Started presentation.
Manufacturing Food
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For more detailed instructions, see the Getting Started presentation.

2. Scale of manufacturing

3. Can you remember?

4. Large-scale production planning
Time
The manufacturer will have deadlines to meet and the product must be produced on time, but storage of the finished product is expensive.
Purchase and storage of materials
Buying ingredients in bulk is cheaper, but they have to be stored and used while they are still fresh. If they are not, wastage increases.
Use of equipment and resources
Equipment is expensive to buy and needs to be used to its full capacity whenever possible. Workers still have to be paid if they have nothing to do, so this must not happen.

5. HACCP What does that stand for?
Hazard Analysis and Critical Control Points
Oh, right! Um, what does that mean then?
It’s a way of making sure things don’t go wrong when we make our products. We have to look carefully at our processes, decide what things might go wrong and find ways to make sure they don’t.
Oh, I see, that makes sense, but how do you actually do it?
First we identify hazards. Those are the things that could go wrong.

6. Hazards What sort of things are hazards?
There could be biological hazards if we didn’t keep food cool enough or left it uncovered where bacteria could get to it.
We also have to avoid things getting into the food that shouldn’t be there – bits of glass from a broken jar, for instance. We call those physical hazards.
Ooh, nasty! What happens if cleaning fluids get into the food?
Those are chemical hazards – we have to watch out for those too.

7. Critical control points
So what can we do about these hazards then?
First of all we find the Critical Control Points.
And they are?
The points in our production process where we can control the hazards.
Can you give me an example please?
After we’ve cooked our pasta sauces, they are obviously hot. If we leave them standing in a warm place, bacteria can grow very quickly.
Oh, I see, so you cool them down really quickly?
That’s right, and we monitor the temperature of the food when we do it. If the results show that the food wasn’t cooled properly (perhaps the refrigeration wasn’t working well), then we have to throw the food away because it might be dangerous.

8. Quality assurance
So HACCP is about making sure that our food is good quality?
That’s right, it’s known as a quality assurance process.

9. HACCP words
Hazard Analysis and Critical Control Points aim to spot the things that might go wrong and build in preventative measures – ways of controlling them.
Hazard
Type
CCP
Preventative measure
Chicken not cooked thoroughly
Biological
Cooking
Monitor cooking times and temperatures
Hair in soup
Physical
Mixing
Staff wear hats
Nail varnish chip on bagel
Packing
No nail varnish allowed
Metal fragments in frozen peas
Scan packs with x-rays
Bleach in cake mix
Chemical
Cleaning
Rinse equipment thoroughly

10. Production charts
A group of students are preparing samosas to serve at a evening of foods from around the world.
Samosas have a filling inside a pastry case.
The filling will be cooked before the samosas are filled.
The samosas will be cooked and served hot.
There will be meat samosas and vegetarian ones.

11. Production charts

12. Production charts

13. Making identical products
When products are mass produced, they all need to be the same (consistent). Some ways of doing this are:
weighing all ingredients and final product to make sure all portions are the correct weight
using computer controlled manufacture (CAM) to keep manufacturing processes consistent
buying in standard components, such as stock cubes, cake mixes and ready-made pastry, from other manufacturers
using moulds and templates to control the shape of products.

14. Making breakfast – The story of cornflakes

15. Cornflakes – quality assurance
The materials used are quality checked before they are used for production.
The production process is carefully monitored following strict schedules, and the results are recorded and analysed.
The product is tested for ‘shelf life’.
Samples are tested routinely to check that the proportion of ingredients is correct using computer controlled analysis.
Experienced tasters meet regularly to compare and taste the cereals being made.
Consumer taste tests are also carried out at the homes of people who eat breakfast cereal regularly.

16. Summary
One-off processing is used by craftsmen to make special products, but it is expensive.
Batch processing makes larger numbers of similar products in batches.
Mass production is used to make large numbers of identical products.
Continuous production machines run all the time.
Hazard Analysis and Critical Control Points are points in the manufacturing process where hazards can be controlled.
Quality assurance is used to make sure products are made to the right standards.